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Simulation Software & Services for Power Generation

Coal Power Generation

ANSYS software for coal power generationAs the economic, political and environment pressures force coal plants to be more efficient and environmentally friendly, SimuTech can provide ANSYS FEA and CFD simulation software and consulting services to help meet these challenges in the coal power generation industry.

Contact us to find out more about how we can help you, and check out the coal power generation design elements we've had experience with below:


engineering simulation software

Design ElementChallengesSimulation Benefits
Pulverizers and Classifiers
  • Control product fineness for low carbon loss, minimal NOx
  • Balance competing forces of mill
    • Efficiency
    • Throughput
    • Power consumption
  • Reduce design time by:
    • Understanding flow patterns to improve design
    • Predicting performance and erosion behavior for varying designs
    • Predicting dynamic behavior, stress, strain for rotating parts
Burners
  • NOx reduction
  • Unburned carbon (LOI)
  • Fatigue and creep from thermal stresses in coal nozzle
  • Reduce design effort and field tests by
    • Predicting temperature, NOx, and LOI with varying fuel, load, swirl
    • Predicting thermal loads and stresses for different designs
Furnaces
  • Maintaining stable flame under varying load conditions
  • Pollutant formation control
  • Maintaining proper radiation and convection properties with retrofitted low NOx burners
  • Optimizing retrofitted air staging
  • Minimizing water wall corrosion
  • Designing optimal spray system for Selective Non-Catalytic Reduction (SNCR)
  • Ensuring retrofit success by predicting
  • Flame shape and thermal loads
  • Impact of various air staging methods
  • Corrosion prone regions
  • SNCR local NOx reduction
  • Avoiding further downtime in a trial-and-error approach
Fluidized Beds
  • Erosion
  • Maximizing gas-solid contact
  • Avoiding channeling
  • Maximizing heat transfer to immersed tubes
  • Creep and fatigue due to thermal stresses
  • Avoid costly problems after manufacture by:
    • Predicting erosion in virtual prototypes
    • Predicting channeling problems
    • Predicting thermal stresses
  • Optimize heat transfer
Gasification
  • Ensuring complete reaction
  • Varying fuels, loads
  • Thermal stresses and heat transfer
  • Carbon capture
  • Gasifier design
    • Impact of inlet positions and flow rates on performance
    • Impact of fuel changes
    • Calculate and design for scale-up effects
Economizers
  • Minimizing erosion and fly-ash buildup
  • Optimizing heat transfer to incoming water
  • Determine areas of likely erosion and fly-ash buildup early in design phase
  • Make flow distribution modifications that will resolve problems before manufacture
Flue Ducts
  • Uneven flow distribution impacting pollution control equipment performance
  • Air leakage
  • Sagging and deformation
  • Optimize vanes and turns for flow distribution prior to manufacturing
  • Ensure deformations will be within limits by testing/optimizing design specs
Selective Catalytic Reduction Systems
  • Poor ammonia/NOx mixing
  • Ammonia slip
  • Hopper fly ash capture efficiency
  • Plugged catalysts
  • Thermal stresses within catalyst beds
  • Retrofit to improve poorly performing existing SCR units without resorting to a trial-and-error approach with physical prototypes. Predict:
    • Ammonia spray distribution, evaporation, and mixing
    • Flow distribution into the catalyst beds
    • Local NOx concentrations
    • Overall system performance
    • Ash and particulate distribution, and hopper performance
    • Thermal stresses
  • Reduce the design cost and increase the performance of new SCR designs
Sulfur Dioxide Scrubbers
  • Poor distribution of spray and/or flue gas
  • Designing spray nozzle placement
  • Improve retrofit and new scrubber performance by using virtual prototyping, predicting:
    • Air and spray droplet flow distribution throughout the scrubber
    • Local sulfur absoprtion and concentration
    • Droplet-wall interaction
Particulate Control
  • Short life of systems and components
  • High cleaning frequency
  • Often caused by:
    • Uneven flow distribution
    • Uneven loading of baghouses, filters, and electrostatic precipitators
  • Determine expected loadings prior to field implementation
  • Determine stresses on components
  • Use results to optimize ducts and turning vanes
  • Few shutdowns
  • Shorter cleaning frequencies
  • Longer bag and plate life